Thick Pointed Superhard Material

ABSTRACT

In one aspect of the invention, a high impact resistant tool having a superhard bonded to a cemented metal carbide substrate at a non-planar interface. The superhard material has a substantially pointed geometry with a sharp apex having 0.050 to 0.125 inch radius measured from a direction substantially perpendicular to a central axis of the tool. The superhard material also has a 0.100 to 0.500 inch thickness from the apex to the non-planar interface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/673,634, which is a continuation-in-part of U.S. patent applicationSer. No. 11/668,254 which was filed on Jan. 29, 2007 and entitled A Toolwith a Large Volume of a Superhard Material. U.S. patent applicationSer. No. 11/668,254 is a continuation-in-part of U.S. patent applicationSer. No. 11/553,338 which was filed on Oct. 26, 2006 and was entitledSuperhard Insert with an Interface. Both of these applications areherein incorporated by reference for all that they contain and arecurrently pending.

BACKGROUND OF THE INVENTION

The invention relates to a high impact resistant tool that may be usedin machinery such as crushers, picks, grinding mills, roller cone bits,rotary fixed cutter bits, earth boring bits, percussion bits or impactbits, and drag bits. More particularly, the invention relates to insertscomprised of a carbide substrate with a non-planar interface and anabrasion resistant layer of super hard material affixed thereto using ahigh pressure high temperature press apparatus. Such inserts typicallycomprise a super hard material layer or layers formed under hightemperature and pressure conditions, usually in a press apparatusdesigned to create such conditions, cemented to a carbide substratecontaining a metal binder or catalyst such as cobalt. The substrate isoften softer than the super hard material to which it is bound. Someexamples of super hard materials that high pressure high temperature(HPHT) presses may produce and sinter include cemented ceramics,diamond, polycrystalline diamond, and cubic boron nitride. A cuttingelement or insert is normally fabricated by placing a cemented carbidesubstrate into a container or cartridge with a layer of diamond crystalsor grains loaded into the cartridge adjacent one face of the substrate.A number of such cartridges are typically loaded into a reaction celland placed in the high pressure high temperature press apparatus. Thesubstrates and adjacent diamond crystal layers are then compressed underHPHT conditions which promotes a sintering of the diamond grains to formthe polycrystalline diamond structure. As a result, the diamond grainsbecome mutually bonded to form a diamond layer over the substrateinterface. The diamond layer is also bonded to the substrate interface.

Such inserts are often subjected to intense forces, torques, vibration,high temperatures and temperature differentials during operation. As aresult, stresses within the structure may begin to form. Drill bits forexample may exhibit stresses aggravated by drilling anomalies duringwell boring operations such as bit whirl or bounce often resulting inspalling, delamination or fracture of the super hard abrasive layer orthe substrate thereby reducing or eliminating the cutting elementsefficacy and decreasing overall drill bit wear life. The superhardmaterial layer of an insert sometimes delaminates from the carbidesubstrate after the sintering process as well as during percussive andabrasive use. Damage typically found in percussive and drag bits may bea result of shear failures, although non-shear modes of failure are notuncommon. The interface between the superhard material layer andsubstrate is particularly susceptible to non-shear failure modes due toinherent residual stresses.

U.S. Pat. No. 5,544,713 by Dennis, which is herein incorporated byreference for all that it contains, discloses a cutting element whichhas a metal carbide stud having a conic tip formed with a reduceddiameter hemispherical outer tip end portion of said metal carbide stud.The tip is shaped as a cone and is rounded at the tip portion. Thisrounded portion has a diameter which is 35-60% of the diameter of theinsert.

U.S. Pat. No. 6,408,959 by Bertagnolli et al., which is hereinincorporated by reference for all that it contains, discloses a cuttingelement, insert or compact which is provided for use with drills used inthe drilling and boring of subterranean formations.

U.S. Pat. No. 6,484,826 by Anderson et al., which is herein incorporatedby reference for all that it contains, discloses enhanced inserts formedhaving a cylindrical grip and a protrusion extending from the grip.

U.S. Pat. No. 5,848,657 by Flood et al, which is herein incorporated byreference for all that it contains, discloses domed polycrystallinediamond cutting element wherein a hemispherical diamond layer is bondedto a tungsten carbide substrate, commonly referred to as a tungstencarbide stud. Broadly, the inventive cutting element includes a metalcarbide stud having a proximal end adapted to be placed into a drill bitand a distal end portion. A layer of cutting polycrystalline abrasivematerial disposed over said distal end portion such that an annulus ofmetal carbide adjacent and above said drill bit is not covered by saidabrasive material layer.

U.S. Pat. No. 4,109,737 by Bovenkerk which is herein incorporated byreference for all that it contains, discloses a rotary bit for rockdrilling comprising a plurality of cutting elements mounted byinference-fit in recesses in the crown of the drill bit. Each cuttingelement comprises an elongated pin with a thin layer of polycrystallinediamond bonded to the free end of the pin.

US Patent Application Serial No. 2001/0004946 by Jensen, although nowabandoned, is herein incorporated by reference for all that itdiscloses. Jensen teaches that a cutting element or insert with improvedwear characteristics while maximizing the manufacturability and costeffectiveness of the insert. This insert employs a superabrasive diamondlayer of increased depth and by making use of a diamond layer surfacethat is generally convex.

BRIEF SUMMARY OF THE INVENTION

In one aspect of the invention, a high impact resistant tool has asuperhard material bonded to a cemented metal carbide substrate at anon-planar interface. At the interface, the substrate has a taperedsurface starting from a cylindrical rim of the substrate and ending atan elevated flatted central region formed in the substrate. Thesuperhard material has a pointed geometry with a sharp apex having 0.050to 0.125 inch radius of curvature. The superhard material also has a0.100 to 0.500 inch thickness from the apex to the flatted centralregion of the substrate. In other embodiments, the substrate may have anon-planar interface. The interface may comprise a slight convexgeometry or a portion of the substrate may be slightly concave at theinterface.

The substantially pointed geometry may comprise a side which forms a 35to 55 degree angle with a central axis of the tool. The angle may besubstantially 45 degrees. The substantially pointed geometry maycomprise a convex and/or a concave side. In some embodiments, the radiusmay be 0.090 to 0.110 inches. Also in some embodiments, the thicknessfrom the apex to the non-planar interface may be 0.125 to 0.275 inches.

The substrate may be bonded to an end of a carbide segment. The carbidesegment may be brazed or press fit to a steel body. The substrate maycomprise a 1 to 40 percent concentration of cobalt by weight. A taperedsurface of the substrate may be concave and/or convex. The taper mayincorporate nodules, grooves, dimples, protrusions, reverse dimples, orcombinations thereof. In some embodiments, the substrate has a centralflatted region with a diameter of 0.125 to 0.250 inches.

The superhard material and the substrate may comprise a total thicknessof 0.200 to 0.700 inches from the apex to a base of the substrate. Insome embodiments, the total thickness may be up to 2 inches. Thesuperhard material may comprise diamond, polycrystalline diamond,natural diamond, synthetic diamond, vapor deposited diamond, siliconbonded diamond, cobalt bonded diamond, thermally stable diamond,polycrystalline diamond with a binder concentration of 1 to 40 weightpercent, infiltrated diamond, layered diamond, monolithic diamond,polished diamond, course diamond, fine diamond, cubic boron nitride,diamond impregnated matrix, diamond impregnated carbide, metal catalyzeddiamond, or combinations thereof A volume of the superhard material maybe 75 to 150 percent of a volume of the carbide substrate. In someembodiments, the volume of diamond may be up b twice as much as thevolume of the carbide substrate. The superhard material may be polished.The superhard material may be a polycrystalline superhard material withan average grain size of 1 to 100 microns. The superhard material maycomprise a 1 to 40 percent concentration of binding agents by weight.The tool of the present invention comprises the characteristic ofwithstanding impacts greater than 80 joules.

The high impact tool may be incorporated in drill bits, percussion drillbits, roller cone bits, shear bits, milling machines, indenters, miningpicks, asphalt picks, cone crushers, vertical impact mills, hammermills, jaw crushers, asphalt bits, chisels, trenching machines, orcombinations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective diagram of an embodiment of a high impactresistant tool.

FIG. 2 is a cross-sectional diagram of an embodiment of a pointedgeometry.

FIG. 2 a is a cross-sectional diagram of another embodiment of asuperhard geometry.

FIG. 3 is a cross-sectional diagram of an embodiment of a superhardgeometry.

FIG. 3 a is a diagram of an embodiment of test results.

FIG. 3 b is diagram of an embodiment of Finite Element Analysis of asuperhard geometry.

FIG. 3 c is diagram of an embodiment of Finite Element Analysis of apointed geometry.

FIG. 4 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 5 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 6 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 7 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 8 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 9 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 10 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 11 is a cross-sectional diagram of another embodiment of a pointedgeometry.

FIG. 12 is a cross-sectional diagram of another embodiment of a highimpact resistant tool.

FIG. 13 is a cross-sectional diagram of another embodiment of a highimpact resistant tool.

FIG. 14 is a cross-sectional diagram of another embodiment of a highimpact resistant tool.

FIG. 14 a is a perspective diagram of an embodiment of high impactresistant tools.

FIG. 15 is a cross-sectional diagram of an embodiment of an asphaltmilling machine.

FIG. 16 is an orthogonal diagram of an embodiment of a percussion bit.

FIG. 17 is a cross-sectional diagram of an embodiment of a roller conebit.

FIG. 18 is a perspective diagram of an embodiment of a mining bit.

FIG. 19 is an orthogonal diagram of an embodiment of a drill bit.

FIG. 20 is a perspective diagram of another embodiment of a trenchingmachine.

FIG. 21 is a cross-sectional diagram of an embodiment of a jaw crusher.

FIG. 22 is a cross-sectional diagram of an embodiment of a hammer mill.

FIG. 23 is a cross-sectional diagram of an embodiment of a verticalshaft impactor.

FIG. 24 is a perspective diagram of an embodiment of a chisel.

FIG. 25 is a perspective diagram of another embodiment of a moil.

FIG. 26 is a cross-sectional diagram of an embodiment of a cone crusher.

DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

FIG. 1 discloses an embodiment of a high impact resistant tool 100 whichmay be used in machines in mining, asphalt milling, or trenchingindustries. The tool 100 may comprise a shank 101 and a body 102, thebody 102 being divided into first and second segments 103, 104. Thefirst segment 103 may generally be made of steel, while the secondsegment 104 may be made of a harder material such as a cemented metalcarbide. The second segment 104 may be bonded to the first segment 103by brazing to prevent the second segment 104 from detaching from thefirst segment 103.

The shank 101 may be adapted to be attached to a driving mechanism. Aprotective spring sleeve 105 may be disposed around the shank 101 bothfor protection and to allow the high impact resistant tool to be pressfit into a holder while still being able to rotate. A washer 106 mayalso be disposed around the shank 101 such that when the high impactresistant tool 100 is inserted into a holder, the washer 106 protects anupper surface of the holder and also facilitates rotation of the tool.The washer 106 and sleeve 105 may be advantageous since they may protectthe holder which may be costly to replace.

The high impact resistant tool 100 also comprises a tip 107 bonded to afrustoconical end 108 of the second segment 104 of the body 102. The tip107 comprises a superhard material 109 bonded to a cemented metalcarbide substrate 110 at a non-planar interface. The tip may be bondedto the substrate through a high temperature high pressure process. Thesuperhard material 109 may comprise diamond, polycrystalline diamond,natural diamond, synthetic diamond, vapor deposited diamond, siliconbonded diamond, cobalt bonded diamond, thermally stable diamond,polycrystalline diamond with a binder concentration of 1 to 40 weightpercent, infiltrated diamond, layered diamond, monolithic diamond,polished diamond, course diamond, fine diamond, cubic boron nitride,diamond impregnated matrix, diamond impregnated carbide, non-metalcatalyzed diamond, or combinations thereof.

The superhard material 109 may be a polycrystalline structure with anaverage grain size of 10 to 100 microns. The cemented metal carbidesubstrate 110 may comprise a 1 to 40 percent concentration of cobalt byweight, preferably 5 to 10 percent. During high temperature highpressure (HTHP) processing, some of the cobalt may infiltrate into thesuperhard material such that the substrate comprises a slightly lowercobalt concentration than before the HTHP process. The superhardmaterial may preferably comprise a 1 to 5 percent cobalt concentrationby weight after the cobalt or other binder infiltrates the superhardmaterial. The superhard material may also comprise a 1 to 5 percentconcentration of tantalum by weight as a binding agent. Other bindersthat may be used with the present invention include iron, cobalt,nickel, silicon, hydroxide, hydride, hydrate, phosphorus-oxide,phosphoric acid, carbonate, lanthanide, actinide, phosphate hydrate,hydrogen phosphate, phosphorus carbonate, alkali metals, ruthenium,rhodium, niobium, palladium, chromium, molybdenum, manganese, tantalumor combinations thereof. In some embodiments, the binder is addeddirectly to the superhard material's mixture before the HTHP processingand do not rely on the binder migrating from the substrate into themixture during the HTHP processing.

Now referring to FIG. 2, the substrate 110 comprises a tapered surface200 starting from a cylindrical rim 250 of the substrate and ending atan elevated, flatted, central region 201 formed in the substrate. Thesuperhard material 109 comprises a substantially pointed geometry 210with a sharp apex 202 comprising a radius of 0.050 to 0.125 inches. Insome embodiments, the radius is 0.900 to 0.110 inches. It is believedthat the apex 202 is adapted to distribute impact forces across theflatted region 201, which may help prevent the superhard material 109from chipping or breaking. The superhard material 109 may comprise athickness 203 of 0.100 to 0.500 inches from the apex to the flattedregion or non-planar interface, preferably from 0.125 to 0.275 inches.The superhard material 109 and the substrate 110 may comprise a totalthickness 204 of 0.200 to 0.700 inches from the apex 202 to a base 205of the substrate 110. The sharp apex 202 may allow the high impactresistant tool to more easily cleave asphalt, rock, or other formations.

The pointed geometry of the superhard material 109 may comprise a sidewhich forms a 35 to 55 degree angle 150 with a central axis of the tool,though the angle 150 may preferably be substantially 45 degrees. Theincluded angle may be a 90 degree angle, although in some embodiments,the included angle is 85 to 95 degrees.

The pointed geometry may also comprise a convex side or a concave side.The tapered surface of the substrate may incorporate nodules 207 at theinterface between the superhard material and the substrate, which mayprovide more surface area on the substrate to provide a strongerinterface. The tapered surface may also incorporate grooves, dimples,protrusions, reverse dimples, or combinations thereof. The taperedsurface may be convex, as in the current embodiment, though the taperedsurface may be concave.

Comparing FIGS. 2 and 3, the advantages of having a pointed apex 202 asopposed to a blunt apex 300 may be seen. FIG. 2 is a representation of apointed geometry which was made by the inventors of the presentinvention, which has a 0.094 inch radius apex and a 0.150 inch thicknessfrom the apex to the non-planar interface. FIG. 3 is a representation ofanother geometry also made by the same inventors comprising a 0.160 inchradius apex and 0.200 inch thickness from the apex to the non-planargeometry. The superhard geometries were compared to each other in a droptest performed at Novatek International, Inc. located in Provo, Utah.Using an Instron Dynatup 9250G drop test machine, the tools were securedto a base of the machine and weights comprising tungsten carbide targetswere dropped onto the superhard geometries. The pointed apex 202 of FIG.2 surprisingly required about 5 times more joules to break than thethicker geometry of FIG. 3.

It was shown that the sharper geometry of FIG. 2 penetrated deeper intothe tungsten carbide target, thereby allowing more surface area of thesuperhard material to absorb the energy from the falling target bybeneficially buttressing the penetrated portion of the superhardmaterial effectively converting bending and shear loading of the diamondsubstrate into a more beneficial quasi-hydrostatic type compressiveforces drastically increasing the load carrying capabilities of thesuperhard material. On the other hand since the embodiment of FIG. 3 isblunter the apex hardly penetrated into the tungsten carbide targetthereby providing little buttress support to the diamond substrate andcaused the superhard material to fail in shear/bending at a much lowerload with larger surface area using the same grade of diamond andcarbide. The average embodiment of FIG. 2 broke at about 130 jouleswhile the average geometry of FIG. 3 broke at about 24 joules. It isbelieved that since the load was distributed across a greater surfacearea in the embodiment of FIG. 2 it was capable of withstanding agreater impact than that of the thicker embodiment of FIG. 3.

Surprisingly, in the embodiment of FIG. 2, when the superhard geometryfinally broke, the crack initiation point 251 was below the radius. Thisis believed to result from the tungsten carbide target pressurizing theflanks of the pointed geometry in the penetrated portion, which resultsin the greater hydrostatic stress loading in the pointed geometry. It isalso believed that since the radius was still intact after the break,that the pointed geometry will still be able to withstand high amountsof impact, thereby prolonging the useful life of the pointed geometryeven after chipping.

FIG. 3 a illustrates the results of the tests performed by Novatek,International, Inc. As can be seen, three different types of pointedinsert geometries were tested. This first type of geometry is disclosedin FIG. 2 a which comprises a 0.035 inch thick superhard geometry and anapex with a 0.094 inch radius. This type of geometry broke in the 8 to15 joules range. The blunt geometry with the radius of 0.160 inches anda thickness of 0.200, which the inventors believed would outperform theother geometries broke in the 20-25 joule range. The pointed geometrywith the 0.094 thickness and the 0.150 inch thickness broke at about 130joules. The impact force measured when the superhard geometry with the0.160 inch radius broke was 75 kilo-newtons. Although the Instron droptest machine was only calibrated to measure up to 88 kilo-newtons, whichthe pointed geometry exceeded when it broke, the inventors were able toextrapolate that the pointed geometry probably experienced about 105kilo-newtons when it broke.

As can be seen, superhard material having the feature of being thickerthan 0.100 inches or having the feature of a 0.075 to 0.125 inch radiusis not enough to achieve the superhard material's optimal impactresistance, but it is synergistic to combine these two features. In theprior art, it was believed that a sharp radius of 0.075 to 0.125 inchesof a superhard material such as diamond would break if the apex were toosharp, thus rounded and semispherical geometries are commercially usedtoday.

The performance of the present invention is not presently found incommercially available products or in the prior art. Inserts testedbetween 5 and 20 joules have been acceptable in most commercialapplications, but not suitable for drilling very hard rock formations

After the surprising results of the above test, Finite Element Analysis(FEA) was performed, the results of which are shown in FIGS. 3 b and 3c. FIG. 3 b discloses the superhard geometry, with a radius of 0.160inches and a thickness of 0.200 inches under the load in which it brokewhile FIG. 3 c discloses the pointed geometry with the 0.094 radius andthe 0.150 inch thickness under the load that it broke under. Asillustrated, each embodiment comprises a superhard material 109, asubstrate 110 and a tungsten carbide segment 103. Both embodiments brokeat the same stress, but due to the geometries of the superhard material109, that VonMises level was achieved under significantly differentloads since the pointed apex 202 distributed the stresses moreefficiently than the blunt apex 300. In FIGS. 3 b and 3 c stressconcentrations are represented by the darkness of the regions, thelighter regions represent lower the stress concentrations and the darkerregions represent greater VonMises stress concentration. As can be seenthe stress in the embodiment of FIG. 3 b is concentrated near the apexand are both larger and higher in bending and shear, while the stress inFIG. 3 c distributes the stresses lower and more efficiently due totheir hydrostatic nature.

Since high and low stresses are concentrated in the superhard materialtransverse rupture is believed to actually occur in the superhardmaterial, which is generally more brittle than the softer carbidesubstrate. The embodiment of FIG. 3 c however has the majority of highstress in the superhard material while the lower stresses are actuallyin the carbide substrate which is more capable of handling thetransverse rupture. Thus, it is believed that the geometry's thicknessis critical to its ability to withstand greater impact forces; if it istoo thick the transverse rupture will occur, but if it is too thin thesuperhard material will not be able to support itself and break at lowerimpact forces.

FIGS. 4 through 10 disclose various possible embodiments comprisingdifferent combinations of tapered surface 200 and conical surface 210geometries. FIG. 4 illustrates the pointed geometry with a concave side450 and a continuous convex substrate geometry 451 at the interface 200.FIG. 5 comprises an embodiment of a thicker superhard material 550 fromthe apex to the non-planar interface, while still maintaining thisradius of 0.075 to 0.125 inches at the apex. FIG. 6 illustrates grooves650 formed in the substrate to increase the strength of interface. FIG.7 illustrates a slightly concave geometry at the interface with concavesides 750. FIG. 8 discloses slightly convex sides 850 of the pointedgeometry while still maintaining the 0.075 to 0.125 inch radius. FIG. 9discloses a flat sided pointed geometry 950. FIG. 10 discloses concaveand convex portions 1050, 1051 of the substrate with a generally flattedcentral portion.

Now referring to FIG. 11, the superhard material 109 (number not shownin the fig.) may comprise a convex surface comprising different generalangles at a lower portion 1100, a middle portion 1101, and an upperportion 1102 with respect to the central axis of the tool. The lowerportion 1100 of the side surface may be angled at substantially 25 to 33degrees from the central axis, the middle portion 1101, which may makeup a majority of the convex surface, may be angled at substantially 33to 40 degrees from the central axis, and the upper portion 1102 of theside surface may be angled at about 40 to 50 degrees from the centralaxis.

FIG. 12 discloses the second segment 104 may be press fit into a bore1200 of the first segment 103. This may be advantageous in embodimentswhich comprise a shank 101 coated with a hard material. A hightemperature may be required to apply the hard material coating to theshank, which may affect a brazed bond between the first and secondsegments 103, 104 when the segments have been brazed togetherbeforehand. The same may occur if the segments are brazed together afterthe coating is applied, wherein a high temperature braze may affect thehard material coating. A press fit may allow the second segment 104 tobe attached to the first segment 103 without affecting any othercoatings or brazes on the tool 100. The depth of the bore 1200 and sizeof the second segment 104 may be adjusted to optimize wear resistanceand cost effectiveness of the tool in order to reduce body wash andother wear to the first segment 103.

FIG. 13 discloses the tool 100 may comprise one or more rings 1300 ofhard metal or superhard material disposed around the first segment, asin the embodiment of FIG. 13. The ring 1300 may be inserted into agroove 1301 or recess formed in the first segment. The ring 1300 mayalso comprise a tapered outer circumference such that the outercircumference is flush with the first segment 103. The ring 1300 mayprotect the first segment 103 from excessive wear that could affect thepress fit of the second segment 104 in the bore 1200 of the firstsegment. The first segment 103 may also comprise carbide buttons orother strips adapted to protect the first segment 103 from wear due tocorrosive and impact forces. Silicon carbide, diamond mixed with brazematerial, diamond grit, or hard facing may also be placed in groove orslots formed in the first segment of the tool to prevent the segmentfrom wearing. In some embodiments, epoxy with silicon carbide or diamondmay be used.

The high impact resistant tool 100 may be rotationally fixed during anoperation, as in the embodiment of FIG. 14. A portion of the shank 101may be threaded to provide axial support to the tool, and so that thetool may be inserted into a holder in a trenching machine, a millingmachine, or a drilling machine. The planar surface of the second segmentmay be formed such that the tip 107 is presented at an angle withrespect to a central axis 1400 of the tool.

FIG. 14 a discloses several pointed insert of superhard materialdisposed along a row. The pointed inserts 210 comprise flats 1450 ontheir periphery to allow their apexes 202 to get closer together. Thismay be beneficial in applications where it is desired to minimize theamount of material that flows between the pointed inserts.

The high impact resistant tool 100 may be used in many differentembodiments. The tool may be a pick in an asphalt milling machine 1500,as in the embodiment of FIG. 15. The pointed inserts as disclosed hereinhave been tested in locations in the United States and have shown tolast 10 to 15 time the life of the currently available milling teeth.

The tool may be an insert in a drill bit, as in the embodiments of FIGS.16 through 19. In percussion bits, the pointed geometry may be useful incentral locations 1651 on the bit face 1650 or at the gauge 1652 of thebit face. Further the pointed geometry may be useful in roller conebits, where the inserts typically fail the formation throughcompression. The pointed geometries may be angled to enlarge the gaugewell bore. FIG. 18 discloses a mining bit that may also be incorporatedwith the present invention. FIG. 19 discloses a drill bit typically usedin horizontal drilling.

The tool may be used in a trenching machine 2000, as in the embodimentof FIG. 20. The tools may be placed on a chain that rotates around anarm 2050.

Milling machines may also incorporate the present invention. The millingmachines may be used to reduce the size of material such as rocks,grain, trash, natural resources, chalk, wood, tires, metal, cars,tables, couches, coal, minerals, chemicals, or other natural resources.

A jaw crusher 2100 may comprise fixed plate 2150 with a wear surface andpivotal plate 2151 with another wear surface. Rock or other materialsare reduced as they travel downhole the wear plates. The inserts may befixed to the wear plates 2152 and may be in larger size as the tools getcloser to the pivotal end of the wear plate. Hammer mills 2200 mayincorporate the tool at on the distal end 2250 of the hammer bodies2251. Vertical shaft impactors 2300 may also use the pointed inserts ofsuperhard materials. They may use the pointed geometries on the targetsor on the edges of a central rotor.

Chisels 2400 or rock breakers may also incorporate the presentinvention. At least one tool with a pointed geometry may be placed onthe impacting end 2450 of a rock breaker with a chisel 2400 or moilgeometry 2500. In some embodiments, the sides of the pointed geometrymay be flatted.

A cone crusher, as in the embodiment of FIG. 26, may also incorporatethe pointed geometries of superhard material. The cone crusher maycomprise a top and bottom wear plate 2650, 2651 that may incorporate thepresent invention.

Other applications not shown, but that may also incorporate the presentinvention include rolling mills; cleats; studded tires; ice climbingequipment; mulchers; jackbits; farming and snow plows; teeth in trackhoes, back hoes, excavators, shovels; tracks, armor piercing ammunition;missiles; torpedoes; swinging picks; axes; jack hammers; cement drillbits; milling bits; drag bits; reamers; nose cones; and rockets.

Whereas the present invention has been described in particular relationto the drawings attached hereto, it should be understood that other andfurther modifications apart from those shown or suggested herein, may bemade within the scope and spirit of the present invention.

1. A high impact resistant tool, comprising a sintered polycrystallinediamond material bonded to a cemented metal carbide substrate at anon-planar interface; the diamond material comprises a substantiallypointed geometry with an apex comprising 0.050 to 0.125 inch radius ofcurvature measured from a direction substantially perpendicular to acentral axis of the tool; the diamond material comprises a 0.100 to0.500 inch thickness from the apex to the non-planar interface; and thecentral axis intersects the interface between the diamond material andsubstrate.
 2. The tool of claim 1, wherein the substantially pointedsurface comprises a side which forms a 35 to 55 degree angle with acentral axis of the tool.
 3. The tool of claim 2, wherein the angle issubstantially 45 degrees.
 4. The tool of claim 1, wherein thesubstantially pointed geometry comprises a convex side.
 5. The tool ofclaim 1, wherein the substantially pointed geometry comprises a concaveside.
 6. The tool of claim 1, wherein at the interface the substratecomprises a tapered surface starting from a cylindrical rim of thesubstrate and ending at an elevated flatted central region formed in thesubstrate.
 7. The tool of claim 6, wherein the flatted region comprisesa diameter of 0.125 to 0.250 inches.
 8. The tool of claim 6, wherein thetapered surface incorporates nodules, grooves, dimples, protrusions,reverse dimples, or combinations thereof.
 9. The tool of claim 1,wherein the radius is 0.090 to 0.110 inches.
 10. The tool of claim 1,wherein the thickness from the apex to the non-planar interface is 0.125to 0.275 inches.
 11. The tool of claim 1, wherein the diamond materialand the substrate comprise a total thickness of 0.200 to 0.700 inchesfrom the apex to a base of the substrate.
 12. The tool of claim 1,wherein a volume of the diamond material is 75 to 150 percent of avolume of the carbide substrate.
 13. The tool of claim 1, wherein thehigh impact tool is incorporated in drill bits, percussion drill bits,roller cone bits, shear bits, milling machines, indenters, mining picks,asphalt picks, cone crushers, vertical impact mills, hammer mills, jawcrushers, asphalt bits, chisels, trenching machines, or combinationsthereof.
 14. The tool of claim 1, wherein the substrate is bonded to anend of a carbide segment.
 15. The tool of claim 1, wherein the diamondmaterial is a polycrystalline structure with an average grain size of 1to 100 mircons.
 16. The tool of claim 1, wherein the diamond materialcomprises a 1 to 5 percent concentration of binding agents by weight.17. The tool of claim 1, wherein the substrate comprises a 5 to 10percent concentration of cobalt by weight.
 18. The tool of claim 1,wherein the tool comprises the characteristic of withstanding impacts of130 joules.
 19. The tool of claim 1, wherein the central axis alsosubstantially intersects the apex of the diamond material.